# US 2014/0153894 A1 · Fabrication of an optical wedge > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0153894 A1 - Document ID: US20140153894A1 - Status: Published application - Kind: A1 - Application number: 14/175,307 - Filed: 2014-02-07 - Published: 2014-06-05 - Earliest claimed: 2010-03-02 - Assignees: Microsoft Corporation - Applicants: Microsoft Corporation - Inventors: Kurt Allen Jenkins; Timothy Large; Rajesh Manohar Dighde - Web page: https://patentgrep.com/patent/US20140153894A1 ## CPC - B29D 11/00663: {Production of light guides} - B29C 59/002: {Component parts, details or accessories; Auxiliary operations} - B29D 11/00932: {Combined cutting and grinding thereof} - G02B 6/10: of the optical waveguide type (G02B6/02, G02B6/24 take precedence; devices or arrangements for the control of light by electric, magnetic, electro-magnetic or acoustic means G02F1/00; transferring the modulation of modulated light G02F2/00; optical logic elements G02F3/00; optical analogue/digital converters G02F7/00) - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS ## Abstract Various embodiments are disclosed relating to fabrication of an optical wedge. For example, one embodiment provides a method for manufacturing an optical wedge comprising inserting a wedge blank into a vacuum molding tool and applying a vacuum to the vacuum molding tool to temporarily hold the wedge blank against a molding surface of the vacuum molding tool. The method further comprises removing a layer from a top surface of the wedge blank to expose a machined surface of the wedge blank, and casting a finish layer on the machined surface to form a finish layer of a finished optical wedge. ## Claims ### Claim 1 A vacuum molding system for forming an optical wedge from a wedge blank, the vacuum molding system comprising: a vacuum pump; a vacuum molding tool comprising one or more vacuum ports fluidly connected to the vacuum pump, the vacuum molding tool including a molding surface configured to temporarily shape a molded surface of the wedge blank under the urging of a pressure differential generated by the vacuum pump; and a casting plate configured to be retained across a finish layer of the wedge blank opposite from the molded surface of the wedge blank. ### Claim 2 (depends on 1) The vacuum molding system of claim 1, wherein the molding surface comprises an optical surface profile to be imparted to the molded surface of the wedge blank. ### Claim 3 (depends on 2) The vacuum molding system of claim 2, wherein the molding surface of the vacuum molding tool includes one or more local topographic characteristics each configured to impart a complementary local topographic feature to the molded surface of the wedge blank. ### Claim 4 (depends on 1) The vacuum molding system of claim 1, wherein the casting plate comprises a float glass plate configured to impart a planar surface to a diffuser interface surface of a finished optical wedge. ### Claim 5 (depends on 4) The vacuum molding system of claim 4, wherein the casting plate comprises a surface roughness average of two nanometers or less. ### Claim 6 (depends on 1) The vacuum molding system of claim 1, further comprising an ionizer gun configured to control one or more electrostatic potentials of the vacuum molding system. ### Claim 7 (depends on 1) The vacuum molding system of claim 1, further comprising a precursor-curing energy source. ### Claim 8 (depends on 7) The vacuum molding system of claim 7, wherein the precursor-curing energy source comprises an ultraviolet lamp. ### Claim 9 (depends on 1) The vacuum molding system of claim 1, further comprising a wedge blank inserted in the vacuum molding tool, the wedge blank comprising a smoother surface in contact with the molding surface and a rougher surface opposite the molding surface. ### Claim 10 (depends on 1) The vacuum molding system of claim 1, further comprising a finish layer applied over the wedge blank, wherein the casting surface is in contact with the finish layer. ### Claim 11 (depends on 1) The vacuum molding system of claim 1, wherein the casting surface comprises a mold release agent. ### Claim 12 (depends on 1) The vacuum molding tool of claim 1, wherein the casting plate has a thickness of 20-25 mm. ### Claim 13 An optical wedge, comprising: a wedge blank comprising a surface having a non-planar shape; and a cured polymer disposed on a surface of the wedge blank opposite the surface having the non-planar shape, wherein the cured polymer comprises an index of refraction of within +/−0.01 of an index of refraction of the wedge blank, and wherein the cured polymer comprises a cast surface. ### Claim 14 (depends on 13) The optical wedge of claim 13, wherein the cast surface comprises a surface roughness average of two nanometers or less. ### Claim 15 (depends on 13) The optical wedge of claim 13, wherein the cast surface is planar, and wherein the surface having the non-planar shape comprises an aspheric optical feature. ### Claim 16 (depends on 13) The optical wedge of claim 13, wherein the cured polymer comprises poly(methyl methacrylate). ### Claim 17 A vacuum molding system for forming an optical wedge from a wedge blank, the vacuum molding system comprising: a vacuum pump; a vacuum molding tool comprising one or more vacuum ports fluidly connected to the vacuum pump, the vacuum molding tool including a molding surface configured to temporarily shape a molded surface of the wedge blank under the urging of a pressure differential generated by the vacuum pump, the molding surface defining an aspheric optical feature; and a casting plate configured to be retained across a finish layer of the wedge blank opposite from the molded surface of the wedge blank. ### Claim 18 (depends on 17) The vacuum molding system of claim 17, wherein the casting plate comprises a float glass plate. ### Claim 19 (depends on 17) The vacuum molding system of claim 17, wherein the casting plate has a thickness of 20-25 mm. ### Claim 20 (depends on 18) The vacuum molding system of claim 18, further comprising an ionizer gun.